Method and system for creating personalized packaging

ABSTRACT

A personalized package creation system uses an imaging device to capture an image of a barcode. An image capture module decodes the barcode to retrieve data, such as package dimension data and one or more package structural parameters. Based on the package dimensions and the structural parameter, a processing device defines a set of cutting instructions. An automated package generation device applies the cutting instructions and uses a cutting device to creating a package.

BACKGROUND

When selecting a package for a product that is to be sold or shipped,product manufacturers and sellers typically must select a package from aspecific inventory of available package sizes and shapes. However, thismay result in a package that is not entirely suitable for the product.For example, when using a package that is larger than the productrequires, additional packaging material may be needed to avoid damage tothe product during handling. In addition, a larger package can requireincreased shipping and handling costs.

Thus, there has been significant interest in the manufacture ofpersonalized packaging for small volume applications. For example, aunique product such as a work of art may benefit from having a uniquepackage. However, the creation of unique packages can require additionalcosts and significant setup time. Current automated packaging solutionsare designed for medium to high volumes, and it is not easy to vary thephysical properties of individual packages within a run of products.This document describes systems and methods that present solutions tothe problems discussed above, and which may also provide additionalbenefits.

SUMMARY

In an embodiment, a method of creating a package uses an imaging deviceto capture an image of a barcode. An image capture module decodes thebarcode to retrieve data, such as package dimension data and one or morepackage structural parameters. Based on the package dimensions and thestructural parameter, a processing device defines a set of cuttinginstructions. An automated package generation device applies the cuttinginstructions and uses a cutting device to creating a package in the formof a package flat.

In some embodiments, when capturing the image, the barcode that theimaging device captures is, at the time of capture, printed on thesubstrate that the cutting device will use to yield the package.

In some embodiments, when defining the set of cutting instructions, theprocessor may retrieve a template from a database based on the packagedimension data and the package structural parameter. The packagestructural parameter may comprise a shape of a facet of the package. Thetemplate may comprise a rule set. When defining the set of cuttinginstructions the processor may apply the shape and the packagedimensions to the rule set to identify additional facets for the packageflat. For each facet, the processor may apply a dimension set and aposition relative to at least one of the other facets. Additionally, foreach facet, the processor may define a set of instructions to createedges. At least one of the edges comprises a cut line, and one or moreother edges comprises a fold line.

Optionally, the processor may select an algorithm based on the anindicator in the barcode and apply the structural parameter to thealgorithm. The structural parameter may include information relating toat least one facet of the package. In some embodiments, it may haveinformation relating to no more than one facet of the package.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example of a printed package flat.

FIG. 2 is an example of a barcode and data that may be encoded in thebarcode.

FIG. 3 is a flowchart describing a process for generating a set ofinstructions for creating a package.

FIG. 4 illustrates an example of a three-dimensional package.

FIG. 5 shows a two-dimensional package flat that corresponds to thethree-dimensional package of FIG. 4.

FIG. 6 is a block diagram showing elements of a computer system that maybe used to implement various embodiments of the processes described inthis document.

DETAILED DESCRIPTION

This disclosure is not limited to the particular systems, devices andmethods described, as these may vary. The terminology used in thedescription is for the purpose of describing the particular versions orembodiments only, and is not intended to limit the scope.

As used in this document, the singular forms “a,” “an,” and “the”include plural references unless the context clearly dictates otherwise.Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of ordinary skillin the art. As used in this document, the term “comprising” means“including, but not limited to.”

For the purposes of this document, a “barcode” refers to anymachine-readable representation of encoded data, such as a UniversalProduct Code (UPC), data matrix code, Quick Response (QR) code or otherone or two-dimensional symbology, glyph, Aztec code, Maxi code and thelike.

An “imaging device” refers to any device capable of optically viewing anobject and converting an interpretation of that object into electronicsignals. One example of an imaging device is a camera lens. An “imagecapture module” refers to the software application and/or the imagesensing hardware of an electronic device that is used to capture imagesof barcodes and other symbologies.

Package production may be performed by a printing device that is capableof performing printing and cutting operations on a substrate. The devicealso may perform other actions such as imparting a crease, coating,and/or stacking. Examples of automated package production devicesinclude those in the iGen™ series of digital production printingpresses, available from Xerox Corporation. Typically, the substrate willbe thicker than ordinary paper. For example, it may be cardboard,cardstock, or another material that will provide a self-supportingthree-dimensional structure when folded into a package.

FIG. 1 shows an example of a printed package flat 10 that an automatedpackage production device may produce. The machine may produce the flatbased on data that is maintained in a package data file, such as packagedimensions and structural features. The device uses the dimensions andfeatures to produce the flat. The flat includes one or more facets suchas sides 11, 12, 13, 18; lids 14, 15; and/or lips 16, 17. When thedevice produces the flat 10 from a larger substrate, it will cut thesubstrate along one or more cut lines (represented as solid lines inFIG. 1, see, e.g., line 20) and score or impress the substrate along oneor more fold lines (represented as dashed lines in FIG. 1, see, e.g.,line 21). Any of these items, such as facets, fold lines, and cut lines,may be considered structural features of the package. Any or all of thestructural features, or combinations of the features, may haveassociated dimensions, such as width and height, that are included inthe package's data file.

The substrate also may include printed content 25 such as letters,numbers, graphics, barcodes, or other material that is printed on thesubstrate. Some or all of the printed content 25 may be printed on thesubstrate before the substrate enters the package production device. Forexample, a barcode may be printed on the substrate, and if so theembodiments described in this document may use the barcode to obtaindata and/or instructions for producing the package.

Barcodes and other data have been used to identify print productionjobs. For example, U.S. Patent Application Publication Numbers.2010/0214622 (Ruegg et al.) and 2008/0273945 (Levine et al.), thedisclosures of which are incorporated by reference, describe methods andsystems for producing books based on material that is printed on thecover. The cover may be scanned to locate printed material that can beused to identify the book, and a book block may then be retrieved from arepository based on the book's identification. The book is then printedbased on raster image processing of the book block.

Automated package production requires much more data than does rasterimage processing of a book block. To produce a package, the productiondevice requires not only content to be printed on the package, but alsostructural parameters and dimensions for each facet of the package.However, it would be impractical to include all of these features in abarcode, as the resulting barcode would need to be unreasonably large tocontain all of the data in encoded form. In addition, it would beimpractical to maintain a database with all possible package structuraldesigns and sizes, as doing so would not permit users to create trulypersonalized packaging, down to a run length of one unique unit.

Thus, the embodiments described in this document include a packagegeneration process in which a barcode is printed on a substrate, such asa substrate from which a package will be cut. FIG. 2 shows an example ofa barcode 201 containing encoded data that may be used to produce apackage. The barcode includes encoded data representing an overall sizeof the package 211, a point of reference for the package 213, and one ormore structural parameters that provide information about at least onefacet of the package 215. The structural parameters 215 may includefeatures such as a type of facet (examples include side, lid or lip) andone or more dimensions of the facet (examples include length and width).

However, the barcode need not include all details about each facet ofthe package. Instead, the barcode need only include details about asubset of the package's facets, such as only one facet of the package. Aprocessor can then use this information to identify the package'sremaining facets and determine instructions for creating the entirepackage. Various features of such a process are illustrated in theflowchart of FIG. 3. First, an image processing device may scan 301 abarcode and decode 303 the data contained in the barcode. As notedabove, the barcode may be printed on the substrate from which thepackage will be formed. Alternatively, the barcode may be printed on aseparate substrate, or presented on an electronic display, so that animaging device may receive the barcode and an image capture module maydecode it. The imaging device and/or image capture module may beelements of the package generation system, or they may be part of one ormore separate devices that directly or indirectly send electronicsignals to the package generation system.

A processor will review the decoded data to identify at least a packagedimension 305 and a package structural parameter 307. These data pointsmay be identified based on metadata, based on a position in the barcode,based on a format of or header associated with the data, or by any othersuitable means. The package dimensions 305 may include an overallmaximum height and/or width (x-coordinate and y-coordinate), a minimumheight and/or width, or any other dimension for a two-dimensionalpackage flat. The structural parameters 307 may include a type ofpackage and/or an identification of one or more facets of the package,such as symmetries or shape. The parameters may include a side, lid, lipor other facet, optionally along with a descriptive element regarding ashape of the facet such as rectangular, square, triangular, or rounded.Optionally, the decoded data also may yield a point of reference 309that the processor may use to identify a point on the substrate. A pointof reference may include one or more coordinates, such as coordinatescorresponding to a location that is x inches up from the bottom leftcorner of the uncut substrate and the bottom left corner of the uncutsubstrate and y inches to the right of that corner. Alternatively, eachsubstrate may have a default point of reference, such as a center point,or a point at a corner of the substrate. In either situation, thestructural parameters also may optionally include a distance away fromthe point of reference. For example, if the point of reference is acenter of the uncut substrate, a structural parameter may indicate thata rectangular facet has an upper left corner that is to be positionedtwo inches to the right of, and five inches above, the center point.

In some embodiments, the encoded data also may include an algorithm 311for the calculation of additional facets and positions of those facets.For example, if the encoded data describes an enclosed box, there may beadditional data that indicates that a lid with overhanging sides is tobe used. If so, then the processor may use the algorithm to process thedata from the barcode and determine the remaining structural features313.

Alternatively, the system may use the known information to identify atemplate 315 from a database that is stored in a computer-readablememory that is in communication with the processor. The template mayinclude a set of rules that allow the processor identify what otherfacets should be generated based on the known information. The templatealso may include one or more algorithms, or one or more standardselections. The processor can then apply the barcode data to thetemplate 317 to identify the remaining structural parameters.

As an example, referring to FIG. 4, if the structural parametersindicate that a three-dimensional package is to be a triangular column401, the barcode also may include data indicating that the packageincludes a triangular facet 405 having a four-inch base edge 407. Thedata also may indicate that an overall width and height of the cuttwo-dimensional flat from which the package will be formed is 10 incheshigh by 10 inches wide. If so, the template may include a rule setindicating that the remaining structural features will include a firstfacet 411 that is adjacent to the base edge 407, and that the first facehas height corresponding to the overall height (10 inches) and a widthcorresponding to the width of the base. The processor may thendetermine, based on rules contained in the template, that the remainingstructural features require two more facets 413 that are each adjacentto the first facet 411 along its 10-inch edge and adjacent to thetriangular facet 405 along its two sides. The height of each side facet413 would equal the total height (10 inches), and the width of each sidefacet 413 would equal (total width−base of triangle width)/2, or 3inches.

Optionally, the template also may indicate that one or more lips (notshown) should be attached to either the triangular facet or any of therectangular facets. The template would define the height, width andother features of each lip based on the dimensions of the facet to whichit is attached. The number of lips and/or lids, and their positions, mayvary based on the overall size of the package. For example, referring toFIG. 1, the template for a square box may include a rule stating that ifthe length of side 18 is ten inches or less, then two lips 17 should bepositioned along the outer edge of side 18, each positioned three inchesfrom an outside corner of side 18. On the other hand, if the length ofside 18 is more than ten but less than twenty inches, then the rule maybe that three lips 17 are required, one of which will be centered alongthe edge of side 18.

In addition, if the column is to be a closed column, the template mayindicate that a second triangular facet having dimensions equal to thoseof the first triangular facet 405 should be provided. An example of howthese features may be represented on a two-dimensional package flat isshown in FIG. 5. In addition to the features shown in FIG. 4, FIG. 5also shows a second side facet 423 and a second triangular facet 425.

In this way, the system can use the barcode data to identify the facets,and dimensions for each facet, of a package without requiring all of thedata to be encoded in the barcode or stored in a package-specific datafile. In some embodiments, no more than 10 characters, 11 characters, or12 characters, will be needed in the barcode. For example, a firstcharacter can be used to identify a media structure type (cube,triangular box 401, compact disc box, etc.), the 3 following characterscan be used to identify an overall first dimension for the package(e.g., width, or distance along an x-axis), the next 3 characters can beused to identify an overall second dimension for the package (e.g.,height, or distance along a y-axis), and the next 3 characters can beused to identify an overall third dimension for the package (e.g.,depth, or distance along a z-axis). The last character could describethe type of lid to be used. Based on this information, the algorithmcould use the rules for the template indicated by the first characteralong with the rest of the data to determine the geometry of thecorresponding cut and fold lines as they would be applied to a packageflat.

Returning to FIG. 3, after the system identifies the dimensions of thepackage flat and its facets, the system may define a set of cuttingand/or scoring instructions 319 that the package generating device mayuse to apply cut lines and/or fold lines to the substrate and save thoseinstructions to a computer readable memory such as a package generationfile. The system may do this by retrieving a group of instructions forthe edges of each facet from an instruction database, modifying groupsas necessary based on each facet's relative position in the package, andthen combining each retrieved group into an overall instruction set forthe package flat. The instructions may include a series of instructionsto either (a) apply a cut or fold line to the substrate, or (b) move thetool to a new position on the substrate without altering the substrate.For example, referring to FIG. 5, the instructions to create lid 405 mayinclude instructions to: (1) move the cutter to the intersection ofsides 421 and 423 of the lid; (2) apply a straight line cut from thatpoint to the intersection of sides 421 and 422; (3) apply anotherstraight line cut from that point to the intersection of sides 422 and423; and (4) apply a straight line crease from that point to theintersection of sides 423 and 421. The system may determine whether aparticular instruction for each facet edge (or portion thereof) shouldbe a line or crease depending on whether that edge is an outer edge ofthe package flat (in which case a cut should be applied), or whether theedge is adjacent to another facet (in which case a crease should beapplied).

Returning to FIG. 3, after the cutting instructions are defined, thepackage generation system may then apply the cutting instructions to thesubstrate 321 to create the package flat.

FIG. 6 depicts a block diagram of internal hardware that may be used tocontain or implement program instructions for the package generationsystem and/or related devices as described above. A bus 600 serves asthe main information highway interconnecting the other illustratedcomponents of the hardware. CPU 605 is the central processing unit ofthe system, performing calculations and logic operations required toexecute a program. CPU 605, alone or in conjunction with one or more ofthe other elements disclosed in FIG. 6 is a processing device, computingdevice or processor as such terms are used within this disclosure. Readonly memory (ROM) 610 and random access memory (RAM) 615 constituteexamples of memory devices or processor-readable storage media.

A controller 620 interfaces with one or more optional tangible,computer-readable memory devices 625 to the system bus 600. These memorydevices 625 may include, for example, an external or internal DVD drive,a CD ROM drive, a hard drive, flash memory, a USB drive or the like. Asindicated previously, these various drives and controllers are optionaldevices.

Program instructions, software or interactive modules for providing theinterface and performing any querying or analysis associated with one ormore data sets may be stored in the ROM 610 and/or the RAM 615.Optionally, the program instructions may be stored on a tangiblecomputer readable medium such as a compact disk, a digital disk, flashmemory, a memory card, a USB drive, an optical disc storage medium, suchas a Blu-ray™ disc, and/or other recording medium.

An optional display interface 640 may permit information from the bus600 to be displayed on the display 645 in audio, visual, graphic oralphanumeric format. Communication with external devices, such as aprinting device, may occur using various communication ports 650. Acommunication port 650 may be attached to a communications network, suchas the Internet or an intranet.

The hardware may also include an interface 655 which allows for receiptof data from input devices such as a keyboard 660 or other input device665 such as a mouse, a joystick, a touch screen, a remote control, apointing device, a video input device and/or an audio input device.

The features and functions disclosed above, as well as alternatives, maybe combined into many other different systems or applications. Variouspresently unforeseen or unanticipated alternatives, modifications,variations or improvements may be made by those skilled in the art, eachof which is also intended to be encompassed by the disclosedembodiments.

1. A method, comprising: by an imaging device, capturing an image of abarcode; by an image capture module, decoding the barcode to retrievedata, wherein the data includes package dimensions and a packagestructural parameter; by a processor based on the package dimensions andthe structural parameter, defining a set of cutting instructions; and byan automated package generation device, creating a package by using acutting device to apply the cutting instructions to a substrate to yielda package flat.
 2. The method of claim 1, wherein the capturingcomprises capturing the image of the barcode as printed on thesubstrate.
 3. The method of claim 1, wherein the defining comprisesretrieving a template from a database based on the package dimensionsand the package structural parameter.
 4. The method of claim 3, whereinthe package structural parameter comprises a shape of a facet of thepackage, the template comprises a rule set, and the defining furthercomprises: applying the shape and the package dimensions to the rule setto identify a plurality of additional facets for the package flat and,for each facet, a dimension set and a position relative to at least oneof the other facets.
 5. The method of claim 4, wherein the definingfurther comprises, for each facet, defining a set of instructions tocreate a plurality of edges, wherein at least one of the edges comprisesa cut line and at least a second of the edges comprises a fold line. 6.The method of claim 1, wherein the defining comprises: selecting analgorithm based on the indicator in the barcode; and applying thestructural parameter to the algorithm.
 7. The method of claim 1, whereinthe package structural parameter comprises information relating to atleast one facet of the package.
 8. The method of claim 1, wherein thepackage structural parameter comprises information relating to no morethan one facet of the package.
 9. An automated package generationsystem, comprising: an image capture module configured decode a barcodeto yield data corresponding to dimensions and a structural parameter fora package; a processor; a cutting device; and a computer-readable memoryholding programming instructions that, when executed, instruct theprocessor to: use the package dimensions and the structural parameter todefine a set of cutting instructions; and instruct the cutting device toapply the cutting instructions to a substrate to yield a two-dimensionalflat of the package.
 10. The system of claim 9, further comprising animaging device configured to capture an image of the barcode from thesubstrate and provide the image to the image capture module for thedecoding.
 11. The system of claim 9: further comprising a databasestoring a plurality of package templates; and wherein the programminginstructions that, when executed, cause the processor to define the setof cutting instructions comprise instructions to select a template fromthe database based on the package dimensions and the package structuralparameter.
 12. The system of claim 11 wherein: each of the packagetemplates comprises a rule set; the package structural parametercomprises a shape of a facet; the template comprises a rule set; and theprogramming instructions that, when executed, cause the processor todefine the set of cutting instructions also comprise instructions to:apply the shape and the package dimensions to the rule set to identify aplurality of additional facets for the package flat; and for each facet,identify a dimension set and a position relative to at least one of theother facets.
 13. The system of claim 12, wherein the programminginstructions that, when executed, cause the processor to define the setof cutting instructions also comprise instructions to, for each facet,define a set of instructions to create a plurality of edges, wherein atleast one of the edges comprises a cut line and at least a second of theedges comprises a fold line.
 14. The system of claim 9, wherein theprogramming instructions that, when executed, cause the processor todefine the set of cutting instructions comprise instructions to: selectan algorithm based on the an indicator in the barcode; and apply thestructural parameter to the algorithm.
 15. The system of claim 9,wherein the package structural parameter comprises information relatingto no more than one facet of the package.
 16. The system of claim 9,wherein the package structural parameter comprises information relatingto at least one facet of the package.
 17. A computer-readable mediumcontaining programming instructions that, when executed, cause aprocessor of an electronic device to: capture an image of a barcode;decode the barcode to retrieve package dimension data and a packagestructural parameter; use the package dimension data and a packagestructural parameter to define a set of cutting instructions; andinstruct an automated package generation device to apply the cuttinginstructions to create a package flat.
 18. The computer-readable mediumof claim 17, wherein the package structural parameter comprises a shapeof a facet of the package, and wherein the instructions that, whenexecuted, cause the processor to define a set of cutting instructionscomprise instructions to: retrieve a template from a database based onthe package dimension data and the package structural parameter; andapply the shape and the package dimensions to the template to identify aplurality of additional facets for the package flat and, for each facet,a dimension set and a position relative to at least one of the otherfacets.
 19. The computer-readable medium of claim 18, wherein theinstructions that, when executed, cause the processor to define a set ofcutting instructions further comprise instructions to create a pluralityof edges, wherein a first subset of the edges comprises cut lines and asecond subset of the edges comprises a fold line.
 20. Thecomputer-readable medium of claim 19, wherein the instructions that,when executed, cause the processor to define a set of cuttinginstructions further comprise instructions to: select an algorithm basedon the an indicator in the barcode; and apply the structural parameterto the algorithm.